Container with cutaway corners

ABSTRACT

The present invention provides a container for holding product therein during shipment, storage, or display and being returned for reuse. The container has a base and perpendicular side walls. The side walls are not attached to each other. The base and side walls are adapted, individually or in combination, to flex so that a second container can be nested within a first container. When the second container is placed within the first container, a portion of the base and the side walls of the first container form an obtuse angle. The base and the side walls are biased to form a right angle before the second container is nested within the first and after the second container is unstacked from the first container.

FIELD OF THE INVENTION

The present invention relates to containers for use in shipping,storing, and/or displaying product, and more particularly, to containersor trays that can be nestably stacked together.

BACKGROUND OF THE INVENTION

A large number of different container structures are utilized bymanufacturers to ship a variety of different products to end users,which may be wholesale or retail customers. These containers may also beused to store and/or display products. Many of these boxes, trays, orlike container carriers have perpendicular side walls in order toefficiently and effectively utilize the internal volume of the containerfor storing or displaying a product while at the same time minimizingthe space needed to store or transport the containers. Additionally,many of these containers are made out of a rigid or semi-rigid materialsuch as plastic to further the transport, support, or display of aproduct. However, these containers, even those with an open top, e.g.,tray-like containers, have the disadvantage of not being able to becompactly stored when not in use. Empty containers that cannot becompactly stored for reuse take up valuable warehouse or storage spaceand also increase shipping costs as they require more space in a vehiclewhile being returned for reuse.

One style of container that does allow for compact storage when not inuse is one that has its side walls obtusely angled out from its bottomor base wall. This style of a container allows empty containers to benested or stacked together in a relatively compact fashion. However, forsome products, these style of containers have the disadvantage ofwasting internal space within the container and not allowing for theeffective display or storage of products. For example, for someproducts, space within the container, particularly near the top of thecontainer, is wasted due to the angling out of the side walls.Additionally, when these style containers are placed next to one anotherfor shipping or storage, space between the containers, particularly atthe bottom of the container is wasted due again to the angling out ofthe side walls. Hence, shipping and storage costs are increased.

Another style of containers have employed a collapsible method forachieving compact storage when not in use, but these types of boxes havethe disadvantage of being required to be assembled or de-assembledbefore or after use, and may also lack other advantageous propertiessuch as the rigidity of a plastic-like material which may be lacking ina cardboard-style container.

Accordingly, there is a need for a container with generallyperpendicular side walls for shipping, storing, and/or displaying aproduct that also allows for the compact storing or nesting of thecontainers or trays when not in use. There is further a need for amethod to produce such a stackable container.

SUMMARY OF THE INVENTION

The present invention provides a container or tray for holding producttherein during shipment, storage, and/or display and being returned forreuse. Specifically, the container has a generally rectangular base andside walls which are normally perpendicular to the base. The side wallsare not attached to each other so that the corners formed between theside walls are cutaway or open. A portion of the base is adapted to flexor pivot so that a second container can be stackably nested within afirst container, thereby saving space for shipping or storage purposes.When the second container is placed within the first container, acentral portion of the base and the side walls of the first containerform an obtuse angle which allows the second container to be nestedwithin the first. Moreover, the base and the side walls are biased,independently or in combination, to form a right angle between the baseand the side walls both before the second container is nested within thefirst and after the second container is unstacked from the firstcontainer. In a preferred embodiment, the container is made out of athermoplastic material which may be a polypropylene foam or any othersuitable material. However, the material from which the container ismade may vary. It is the inherent properties of the material from whichthe container is made which enable the side walls to spring back orreturn to their original positions after one or more inner trays orcontainers is/are removed from the interior of the outside container.

In one embodiment, the base of the container or tray has a plurality ofaligned openings therethrough positioned near the intersection of theside walls and the base, i.e., near the right angle formed between anouter portion of the base and the side walls. These openings, which maybe any desired shape or configuration, facilitate the flexing orpivoting of the container side walls to allow multiple containers to benested and stacked together.

In another embodiment, the base of the container or tray has a pluralityof aligned tabs formed by C-shaped cuts therethrough positioned near theintersection of the side walls and the base, i.e., near the right angleformed between an outer portion of the base and the side walls. Thesetabs, which may be any desired shape or configuration, facilitate theflexing or pivoting of the container sidewalls relative to a centralportion of the base to allow multiple containers to be nested andstacked together.

The present invention also provides for a stack of containers nestablystacked inside each other, each having a base and a plurality of sidewalls, which are not attached to each other, but which are integral withthe base. The base and the side walls of at least one outer containerform an obtuse angle allowing additional containers to be nested insidethe outer container or containers. The base and the side walls,individually or in combination, are biased so that the container sidewalls form right angles with a central portion of the base beforeanother container is nested inside the container and also after thecontainers are separated.

The nestably stackable containers of the present invention can be formedby providing a blank and a heat source, heating the blank with the heatsource along fold lines, bending the blank along the fold lines wherebyside walls are formed perpendicular to the base and extending upwardlyfrom the base. The base and side walls are then allowed to cool in theirpreferred orientation or position. In a preferred embodiment, athermoplastic material is used to form the container which enables thecontainer to return to its original position after being emptied ofother containers. Additionally, a plurality of openings may be createdin the base by removing material from select locations of the blank.Alternatively, a plurality of tabs may be created in the base by cuttingthe blank at select locations in predetermined shapes or configurations.The openings or tabs create hinges or pivot points about which the sidewalls hinge or pivot when another like container is nestably stackedtherein.

The present invention provides a box, container or tray which has sidewalls which are sturdy or strong enough to keep objects therein andwhich is also nestably stackable. The above and other objects andadvantages of the present invention shall be made apparent from theaccompanying drawings and the description thereof.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate embodiments of the invention and,together with a general description of the invention given above and thedetailed description of the embodiments given below, serve to explainthe principles of the invention.

FIG. 1 is a perspective view of a preferred embodiment of the containerof the present invention;

FIG. 1A is a cross-sectional view taken of line 1A-1A of FIG. 1;

FIG. 1B is a cross-sectional view of a portion of a stack of containersshown in FIGS. 1 and 1A;

FIG. 2 is a perspective view of another embodiment of container inaccordance with the present invention;

FIG. 2A is a cross-sectional view taken of line 2A-2A of FIG. 2.;

FIG. 2B is a cross-sectional view of a portion of the container shown inFIGS. 2 and 2A being flexed when additional like containers are nestedwithin it;

FIG. 3 is a perspective view of another embodiment of container inaccordance with the present invention;

FIG. 3A is a cross-sectional view taken of line 3A-3A of FIG. 3;

FIG. 3B is a cross-sectional view of a portion of the container shown inFIGS. 3 and 3A being flexed when additional like containers are nestedwithin it;

FIG. 4 is a perspective view of a flat blank used to form the containershown in FIGS. 2 and 2A before the side walls are bent into position;

FIG. 4A is a perspective view of another blank used to form thecontainer shown in FIGS. 2 and 2A before its side walls are bent intoposition;

FIG. 4B is a perspective view of another blank used to form thecontainer shown in FIGS. 3 and 3A before its side walls are bent intoposition;

FIG. 5 is a perspective view showing the blank shown in FIG. 4positioned over a heat source; and

FIG. 6 is a perspective view of the tray shown in FIGS. 1 and 1A,showing a first side wall being bent into position.

DETAILED DESCRIPTION OF THE INVENTION

Referring to FIG. 1, there is illustrated a container or tray 10according to one embodiment of the present invention. The container 10comprises a base 12 and a plurality of side walls 14, 16, 18 and 20, allextending upwardly from the perimeter of the base 12 and beingperpendicular to the base 12. The base 12 and side walls 14, 16, 18 and20 define an interior 21 of the container 10 for storing or displayingproducts or items (not shown). The side walls 14, 16, 18, 20 each areillustrated with at least one aperture or hole 22 which may be used ashandles for transporting the container 10. If desired, the handles maybe omitted on one or more side walls. Alternatively, any number ofhandles of any shape or configuration may be incorporated into thecontainer 10.

As shown in FIG. 1A, the side walls, 14, 16, 18 and 20 are not attachedto each other. Hence, the container 10 has open or cutaway corners 24.Although one configuration or shape of openings at the corners 24 isillustrated, the open corners 24 may be other sizes or shapes. The sidewalls 14, 16, 18 and 20 are connected to the base 12 at a fold line 27and form a right angle 28 with the base member 12. See FIGS. 1 and 1A.The side walls 14, 16, 18 and 20 have upper edges 30, 32, 34 and 36,respectively. Although the upper edges of the side walls are illustratedas being co-planar due to the side walls being the same height, the sidewalls may be different heights if desired, in which case the upper edgesof the side walls would not be co-planar. This may be the case in any ofthe embodiments described herein.

As shown in FIG. 1B, when a second container 11 like the container 10,having a base 13 and sidewalls 15 is nested inside the interior 21 ofthe outer container 10, the side walls 14, 16, 18 and 20 of the outercontainer 10 flex outward about a flex or pivot point 26 located alongbase 12. See FIG. 1B. FIG. 1B also shows a third tray or container 17having a base 19 and sidewalls 23 nested or nestably stacked within thesecond container 11. The second and third containers 11 and 17 are shownin FIG. 1B in dashed lines. Due, at least in part to the inherent natureof the thermoplastic material from which the container 10 is made, theside walls 14, 16, 18, 20 of the container 10 return to their positionshown in FIG. 1A after the containers 11 and 17 are taken out or removedfrom the interior 21 of the container 10. Although two containers 11 and17 are shown nestably stacked inside container 10, any number ofcontainers may be nestably stacked together to save space duringshipping and/or storage.

FIG. 2 shows an alternative embodiment of the present invention. In thisembodiment, like parts will be described with like numbers to thosedescribed above but with an “a” designation after the number. In thisembodiment, container 10 a comprises a base 12 a and a plurality of sidewalls 14 a, 16 a, 18 a and 20 a, all extending upwardly from theperimeter of the base 12 a and being perpendicular to the base 12 a. Thebase 12 a and side walls 14 a, 16 a, 18 a and 20 a define an interior 21a of the container 10 a for storing or displaying products or items (notshown). The side walls 14 a, 16 a, 18 a, 20 a each are illustrated withat least one aperture or hole 22 a used as handles for transporting thecontainer 10 a. If desired, the handles may be omitted on one or moreside walls. Alternatively, any number of handles of any shape orconfiguration may be incorporated into the container 10 a.

As shown in FIG. 2, the side walls 14 a, 16 a, 18 a and 20 a are notattached to each other. Hence, the container 10 a has open or cutawaycorners 24 a. Although one configuration or shape of openings at thecorners 24 a is illustrated, the open corners 24 a may be other sizes orshapes. The side walls 14 a, 16 a, 18 a, and 20 a are connected to thebase 12 a along a fold line 27 a and each side wall forms a right angle28 a with the base 12 a. See FIGS. 2 and 2A. The side walls 14 a, 16 a,18 a and 20 a have upper edges 30 a, 32 a, 34 a and 36 a, respectively.

The base 12 a of the container 10 a shown in FIGS. 2, 2A and 2B has aplurality of aligned tabs 40 formed by C-shaped cuts 42 through the base12 a. The tabs 40 are located generally near the intersection betweenthe base 12 a and the side walls 14 a, 16 a, 18 a and 20 a. Although thetabs 40 are illustrated as being in a generally C-shape and a particularsize, the shape and size of the tabs 40 may be different than as isshown. These tabs 40, as shown in FIG. 2B, provide a pivot point,further facilitate the flexing of the side walls of the container 10 ato allow multiple containers to be nested and stacked together.

As shown in FIG. 2B, when a second container 11 a like the container 10a, having a base 13 a and sidewalls 15 a is nested inside the interior21 a of the outer container 10 a, the side walls 14 a, 16 a, 18 a and 20a of the outer container 10 a flex outward about a flex or pivot point26 a along the base 12 a. See FIG. 2B. Due, at least in part due to theposition of the tabs 40, an outer portion 44 of the base 12 a, alongwith the side walls flexes or pivots about a pivot point 19 a. FIG. 2Balso shows a third tray or container 17 a having a base 19 a andsidewalls 23 a nested or nestably stacked within the second container 11a. The second and third containers 11 a and 17 a are shown in FIG. 2B indashed lines. Due, at least in part to the inherent nature of thethermoplastic material from which the container 10 is made, the sidewalls 14 a, 16 a, 18 a and 20 a of the container 10 a return to theirposition shown in FIG. 2A after the containers 11 a and 17 a are takenout or removed from the interior 21 a of the container 10 a. Althoughtwo containers 11 a and 17 a are shown nestably stacked inside container10 a, any number of containers may be nestably stacked together to savespace during shipping and/or storage.

FIG. 3 shows yet another embodiment of the present invention. In thisembodiment, like parts will be described with like numbers to thosedescribed above but with an “b” designation after the number. In thisembodiment, container 10 b comprises a base 12 b and a plurality of sidewalls 14 b, 16 b, 18 b and 20 b, all extending upwardly from theperimeter of the base 12 b and being perpendicular to the base 12 b. Thebase 12 b and side walls 14 b, 16 b, 18 b and 20 b define an interior 21b of the container 10 b for storing or displaying products or items (notshown). The side walls 14 b, 16 b, 18 b, 20 b each are illustrated withat least one aperture or hole 22 b used as handles for transporting thecontainer 10 b. Of course, the handles may be omitted on any side wall,if desired. Alternatively, any number of handles of any shape orconfiguration may be incorporated into the container 10 b.

As shown in FIG. 3, the side walls 14 b, 16 b, 18 b and 20 b are notattached to each other. Hence, the container 10 b has open or cutawaycorners 24 b. Although one configuration or shape of openings at thecorners 24 b is illustrated, the open corners 24 b may be other sizes orshapes. The side walls 14 b, 16 b, 18 b, and 20 b are connected to thebase 12 b along a fold line 27 b and each side wall forms a right angle28 b with the base 12 b. See FIGS. 3 and 3A. The side walls 14 b, 16 b,18 b and 20 b have upper edges 30 b, 32 b, 34 b and 36 b, respectively.

The base 12 b of the container 10 b shown in FIGS. 3, 3A and 3B has aplurality of aligned generally rectangular openings 46 created byremoving material from the base 12 b. The openings 46 are locatedgenerally near the intersection between the base 12 a and the side walls14 a, 16 a, 18 a and 20 a. Although the openings 46 are illustrated asbeing a particular shape and a particular size, the shape and size ofthe openings 46 may be different than as is shown. These openings 46, asshown in FIG. 3B, provide a pivot point, further facilitate the flexingof the side walls of the container 10 a to allow multiple containers tobe nested and stacked together.

As shown in FIG. 3B, when a second container 11 b like the container 10b, having a base 13 b and sidewalls 15 b is nested inside the interior21 b of the outer container 10 b, the side walls 14 b, 16 b, 18 b and 20b of the outer container 10 b flex outward about a flex or pivot point19 b along the base 12 b. See FIG. 3B. Due, at least in part due to theposition of the openings 46, an outer portion 48 of the base 12 b, alongwith the side walls flexes or pivots about a pivot point 26 b. FIG. 3Balso shows a third tray or container 17 b having a base 19 b andsidewalls 23 b nested or nestably stacked within the second container 11b. The second and third containers 11 b and 17 b are shown in FIG. 3B indashed lines. Due, at least in part to the inherent nature of thethermoplastic material from which the container 10 b is made, the sidewalls 14 b, 16 b, 18 b and 20 b of the container 10 b return to theirposition shown in FIG. 3A after the containers 11 b and 17 b are takenout or removed from the interior 21 b of the container 10 b. Althoughtwo containers 11 b and 17 b are shown nestably stacked inside container10 b, any number of containers may be nestably stacked together to savespace during shipping and/or storage.

FIGS. 4-6 illustrate the method of making container 10. The first stepin the method is providing a blank 50 die cut or otherwise formed from aflat piece of stock. Handles 22 may be cut from the blank 50, ifdesired. In a preferred embodiment, the blank 50 is made ofpolypropylene foam. However, any like thermoplastic material could beused with the claimed process. Polyethylene is advantageous because itis a thermoplastic material which allows it to be heated, bent, and thenretains its new shape when cooled. Polyethylene is a non-brittlethermoplastic which allows the container to have greater flexibilitywhen multiple containers are nested together and it also has a surfacetemperature which is appropriate for many container applications.

As shown in FIG. 5, the blank 50 is positioned over a heat source 52which may be a wire, light source, or other like heating mechanism. FIG.5 illustrates a pair of heated wires 54 as the heat source 52. The blank50 and the heat source 52 are positioned so that the heat source 52 willheat the blank 50 along desired fold lines. Once the blank 50 issufficiently heated, as shown in FIG. 5, the side wall 14 is bent upwardalong the fold line 27 thereby creating a side wall 14 perpendicular tothe base 12. After the blank 50 is bent into shape, it is allowed tocool. Once it cools, it will retain its new shape. The process can thenbe repeated for each of the other side walls 16, 18 and 20 until acontainer or tray is completely formed.

As shown in FIG. 4A, the method may include a step of creating aplurality of tabs 42 in the blank 50 and more particularly in thecentral portion of the blank 50 which becomes the base 12 when thecontainer 10 a is formed. As shown in FIG. 4A, a cutting tool 56 may bemoved relative to a stationary blank 50 or alternatively, the blank 50may be moved relative to a stationary cutting tool 54 to cut the blank50 at the desired locations to form the tabs 40.

As shown in FIG. 4B, the method may include a step of creating aplurality of openings 42 in the blank 50 and more particularly in thecentral portion of the blank 50 which becomes the base 12 when thecontainer 10 b is formed. As shown in FIG. 4B, a cutting tool 58 may bemoved relative to a stationary blank 50 or alternatively, the blank 50may be moved relative to a stationary cutting tool 58 to cut the blank50 at the desired locations to form the openings 46.

While various embodiments of the present invention have been illustratedand described in considerable detail, it is not the intention of theapplicant to restrict or in any way limit the scope of the claims tosuch detail. Additional advantages and modifications will readily appearto those skilled in the art. The invention in its broader aspect is,therefore, not limited to the specific details, representative system,apparatus, and method, and illustrative example shown and described.Accordingly, departures may be made from such details without departingfrom the spirit or scope of the applicant's general inventive concept.

1. A first stackable container comprising: a base; a plurality of sidewalls integral with the base and extending upwardly from the base, theside walls being unattached to one another and perpendicular to thebase; wherein the side walls are adapted to flex outwardly upon a secondstackable container being nested within the first stackable container.2. The first stackable container of claim 1 wherein a portion of thebase and the side walls of the first stackable container form an obtuseangle when the second stackable container is nested within the firststackable container.
 3. The first stackable container of claim 1 whereinthe base and the side walls are biased to form a right angle between thebase and the side walls before the second stackable container is nestedwithin the first stackable container and after the second stackablecontainer is removed from inside the first stackable container.
 4. Thefirst stackable container of claim 1 wherein the first stackablecontainer is made of a thermoplastic material.
 5. The first stackablecontainer of claim of claim 1 wherein the first stackable container ismade of polypropylene foam.
 6. The first stackable container of claim ofclaim 1 wherein the base has a plurality of openings therethrough. 7.The first stackable container of claim of claim 1 wherein the base has aplurality of tabs.
 8. The first stackable container of claim of claim 1wherein the base has a hinge which enables the side walls to pivot aboutthe hinge when another container is nested inside the first stackablecontainer.
 9. The first stackable container of claim of claim 8 whereinmaterial has been removed from the base to define the hinge.
 10. Thefirst stackable container of claim of claim 1 wherein an outside portionof the base and each sidewall remain perpendicular to each other afterat least one other container is nested inside the first stackablecontainer.
 11. A stack of containers adapted for holding a productcomprising: a first and second container each having a base and aplurality of side walls, the side walls being unattached to one another;wherein the second container is nested inside the first container suchthat a portion of the base and side walls of the first container form anobtuse angle.
 12. The stack of containers of claim 11 wherein the baseand the side walls of each of the containers are biased to form a rightangle between the base and the side walls before the containers arenested together and after the containers are separated.
 13. The stack ofcontainers of claim 11 wherein the containers are made of athermoplastic material.
 14. The stack of containers of claim 11 whereinthe containers are made of polypropylene foam.
 15. The stack ofcontainers of claim 11 wherein the bases of the containers have openingstherethrough.
 16. The stack of containers of claim 11 wherein the basesof the containers have tabs formed therein.
 17. A method for making astackable container comprising the steps of: providing a blank and aheat source; heating the blank with the heat source along fold lines;bending the blank at the fold lines so as to create a container having abase and side walls perpendicular to the base, the side walls beingunattached to each other; and allowing the base and side walls to cool.18. The method of claim 17 wherein heating the blank along fold linescomprises heating a blank of thermoplastic material along fold lines.19. The method of claim 17 further comprising the step of creating aplurality of openings in the base.
 20. The method of claim 17 furthercomprising the step of creating a plurality of tabs in the base.